US20110311371A1 - Methods and apparatus for coupling capacitors - Google Patents

Abstract

A method for supplying a plurality of capacitance values to a plurality of heating, ventilation, air-conditioning, and refrigeration (HVAC/R) components is provided. The method includes configuring a first set of terminals of a connection device to couple a first capacitor to the connection device and configuring the connection device to couple the first capacitor to at least one of the plurality of HVAC/R components. The method further includes configuring a second set of terminals of the connection device to couple a second capacitor to the connection device and configuring the connection device to selectively couple the second capacitor to at least one of the plurality of HVAC/R components.

Description

BACKGROUND OF THE INVENTION
• This invention relates generally to servicing of heating, ventilation, air-conditioning, and refrigeration (HVAC/R) systems, and more specifically, to replacement of capacitors included in HVAC/R units.
• A typical HVAC/R system includes a cooling unit having a condenser motor and a compressor motor. Condenser motors and compressor motors are often permanent split-capacitor motors. Capacitors couple the condenser motor and the compressor motor to control circuitry.
• After receiving a service call for a non-operational HVAC/R system located at a remote site, a typical troubleshooting tactic used by a service technician is to first replace a capacitor of a non-operational motor since the capacitor is a component that may fail and is relatively inexpensive compared to the control circuitry and the motor. However, given the large variety of motors currently in use in HVAC/R systems, the service technician would need to carry a large inventory of capacitors, sometimes including large, often expensive, multi-capacitance capacitors, to remote sites to ensure possession of the capacitor ratings needed to repair every HVAC/R system in use. Should the service technician not have a needed capacitor ratings in his “on-site” inventory of capacitors, returning to a repair center or electronics store to obtain the correct capacitor is neither efficient nor cost-effective.
• The problem of having the necessary parts “on-site” has been accentuated by the wider variety of motors and compressors being used in HVAC/R systems due to rising energy efficiency minimum requirements, which are set by government entities. To ensure efficient and cost effective service of HVAC/R systems in the field, a service technician must carry a large number of replacement components, potentially including multi-capacitance capacitors, to a service site.
BRIEF DESCRIPTION OF THE INVENTION
• In one embodiment, a method for supplying a plurality of capacitance values to a plurality of heating, ventilation, air-conditioning, and refrigeration (HVAC/R) components is provided. The method includes configuring a first set of terminals of a connection device to couple a first capacitor to the connection device and configuring the connection device to couple the first capacitor to at least one of the plurality of HVAC/R components. The method further includes configuring a second set of terminals of the connection device to couple a second capacitor to the connection device and configuring the connection device to selectively couple the second capacitor to at least one of the plurality of HVAC/R components.
• In another embodiment, a connection device for selectively coupling a plurality of capacitors to a plurality of components included in a heating, ventilation, air-conditioning, and refrigeration (HVAC/R) system is provided. The connection device includes a first conductor operable to couple a first contact of a first capacitor to a first HVAC/R component, a second conductor operable to couple a second contact of said first capacitor to a second HVAC/R component, and a third conductor operable to selectively couple a first contact of a second capacitor to one of said first HVAC/R component and said second HVAC/R component.
• In another embodiment, a maintenance kit for servicing heating, ventilation, air-conditioning, and refrigeration (HVAC/R) systems, wherein the HVAC/R system includes a plurality of components, is provided. The kit includes a plurality of capacitors of varied ratings, the plurality of capacitors selected to provide predetermined capacitance values when coupled. The kit also includes a connection device configured to couple capacitors selected from the plurality of capacitors to at least one component of the HVAC/R system.
• In another embodiment, a heating, ventilation, air-conditioning, and refrigeration (HVAC/R) condensing unit is provided. The HVAC/R condensing unit includes a compressor motor, a condensing fan motor, control circuitry configured to provide power to, and control operation of, the compressor motor and the condensing fan motor, and a connection device configured to couple the control circuitry, the compressor motor, and the condensing fan motor through at least one capacitor.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a schematic block diagram of a condenser unit of a heating, ventilation, and air-conditioning (HVAC/R) system;
• FIG. 2 is a circuit diagram of a capacitor connection device;
• FIG. 3 is a top view of a capacitor connection device;
• FIG. 4 is a side view of the capacitor connection device ofFIG. 3;
• FIG. 5 is a perspective view of the exemplary capacitor connection device ofFIGS. 3 and 4;
• FIG. 6 is a diagram illustrating a connection of the exemplary capacitor connection device ofFIGS. 3-5 to capacitors; and
• FIG. 7 is a view of an exemplary embodiment of a capacitor maintenance kit.
DETAILED DESCRIPTION OF THE INVENTION
• A residential heating, ventilation, air-conditioning, and refrigeration (HVAC/R) system typically includes a condenser unit, or air conditioning unit, positioned outside of a structure, (e.g., a house, a building, a warehouse, etc.) that is to be cooled.FIG. 1 is a block diagram of a knowncondenser unit10 positioned adjacent to astructure12 having aninterior14 and anexterior16. One purpose of an HVAC/R system andcondenser unit10 is to control the climate ofinterior14 ofstructure12.Condenser unit10 is positionedexterior16 tostructure12.
• Condenser unit10 typically includes two electric motors. Acompressor motor20 and acondenser motor22. Compressor motor20 (also referred to as a hermetic unit) compresses a refrigerant, causing the temperature of the refrigerant to rise. The hot refrigerant gas is provided to acondenser coil26.Condenser motor22 turns an impeller (not shown inFIG. 1) to circulate air across thecondenser coil26, reducing the temperature of the refrigerant within thecondenser coil26.
• Typically, bothcompressor motor20 andcondenser motor22 require a capacitor (not shown inFIG. 1) for starting and/or runningmotors20 and22. Each motor may utilize a capacitor having a different capacitance value. An example of a type of capacitor used within HVAC/R systems is, but is not limited to, an AC film capacitor. Knowncondenser units10 use dual capacitor units that provide two fixed capacitance values within one package. A large number of capacitors having a variety of different capacitance values are currently being used incondenser units10 due to the large variety ofcondenser units10 that are currently in use and eachdifferent condenser unit10 may includedifferent motors20 and22, depending on factors such as the size of thestructure12 to be cooled and the climate of the structure's12 location. As described above, on-site service and maintenance of HVAC/R systems is complicated by the large number ofdifferent motors20 and22 being used in HVAC/R systems.
• FIG. 2 is a circuit diagram of an exemplarycapacitor connection device100.Capacitor connection device100 includes a first set ofterminals110, a second set ofterminals112, and aselection device114.Capacitor connection device100 also includes at least one output terminal, for example, acompressor motor connector116 and acondenser motor connector118.Compressor motor connector116 andcondenser motor connector118 may each be a set of quick connect terminals of a standard configuration, and are used in the same manner as typical capacitor connectors.
• In the exemplary embodiment, the first set ofterminals110 includes three terminals, acondenser motor terminal120, acompressor motor terminal122, and acommon terminal124.Condenser motor terminal120 is electrically coupled tocondenser motor connector118.Compressor motor terminal122 is electrically coupled tocompressor motor connector116. In use, a capacitor is coupled toconnection device100 throughcondenser motor terminal120 andcompressor motor terminal122. In an exemplary embodiment, the three terminals of a dual-rated capacitor unit (not shown inFIG. 2) are coupled toconnection device100 through the first set ofterminals110. The dual-rated capacitor unit (not shown inFIG. 2) provides a first capacitance value tocondenser motor terminal120 and a second capacitance value tocompressor motor terminal122. In an alternative embodiment, multiple capacitors may be coupled to the first set ofterminals110, for example, one terminal of a first capacitor coupled tocondenser motor terminal120, one term of a second capacitor coupled tocompressor motor terminal122, and the common terminals of both the first and second capacitors coupled tocommon terminal124.
• The second set ofterminals112 includes two terminals, an additionalcapacitance value terminal130 and acommon terminal132. In the exemplary embodiment,common terminal132 is coupled tocommon terminal124 and coupled to a ground voltage (not shown) by, for example, awire126. Additionalcapacitance value terminal130 is coupled toselection device114.Selection device114 selectably couples additionalcapacitance value terminal130 to eithercompressor motor terminal122 orcondenser motor terminal120.
• In the exemplary embodiment,selection device114 is a flying lead wire that includes a quick disconnect terminal configured to couple eithercompressor motor connector116 orcondenser motor connector118 to additionalcapacitance value terminal130. In alternative embodiments,selection device114 is a switch (not shown inFIG. 2) that selectively couples additionalcapacitance value terminal130 to eithercompressor motor connector116 orcondenser motor connector118. Other known switching devices may be used so long as the switching device allowsconnection device100 to function as described herein.
• Selection device114 also includes anindication134 as to which ofcompressor motor connector116 andcondenser motor connector118 additionalcapacitance value terminal130 is coupled. In one exemplary embodiment,selection device114 is marked with the legend “ADD TO HERM” and “ADD TO FAN.” Clear labeling ensures that a user ofconnection device100 is certain where the additional capacitance value will be added.
• Selection device114 couples eithercompressor motor connector116 orcondenser motor connector118 to additionalcapacitance value terminal130 dependent upon a user's selection as to where additional capacitance is to be added.Compressor motor connector116 andcondenser motor connector118 provide a connection to an air conditioning or refrigeration unit, for example,condenser unit10. More specifically,compressor motor connector116 accepts a connector commonly used to couple a compressor to a capacitor andcondenser motor connector118 accepts a connector commonly used to couple a condenser to a capacitor. In a specific embodiment,compressor motor connector116 is a triple blade quick connect terminal andcondenser motor connector118 is a dual blade quick connect terminal, which are currently used to connect a capacitor to a compressor and a condenser.
• FIGS. 3-5 are multiple views of the exemplary embodiment ofcapacitor connection device100. Components that are the same inFIG. 2 andFIGS. 3-5 are identified with the same reference numerals. In the embodiment ofFIGS. 3-5,capacitor connection device100 is enclosed within a plastic moldedbox148 that includes the terminals described above.Connection device100 is also provided with two mountingslots150 and152 that can be used to secure theconnection device100 to the HVAC/R unit. In alternative embodiments, any enclosure and associated mounting devices may utilized as long ascapacitor connection device100 is allowed to function as described herein.
• FIG. 6 is a diagram of a top view ofcapacitor connection device100 coupled to afirst capacitor200 and asecond capacitor202.First capacitor200 is a dual capacitor that, as described above, provides two capacitance values. In an exemplary embodiment,first capacitor200 is a dual rated capacitor.Second capacitor202 is a single capacitor, providing a single capacitance value.
• Thefirst capacitor200 has three distinctive and well-identified terminals. Afirst terminal206 is identified with the label “FAN” for where condensingmotor22 is connected; asecond terminal208 is identified with the label “HERM” for where thecompressor motor20, also referred to the Hermetic Unit, is connected; and athird terminal210 identified with the letter “C” indicating a common terminal.
• To utilizecapacitor connection device100,first terminal206 of thefirst capacitor200 is coupled tocondenser motor terminal120. Additionally,second terminal208 of thefirst capacitor200 is coupled tocompressor motor terminal122, andthird terminal210 of thefirst capacitor200 is coupled tocommon terminal124. Similarly, afirst terminal220 ofsecond capacitor202 is coupled to the additionalcapacitance value terminal130 and asecond terminal222 ofsecond capacitor202 is coupled tocommon terminal132.
• Capacitor connection device100 operated to interconnect capacitors having individual capacitance values, to create a single or dual rated capacitor with the one or two specific capacitance values needed for a particular application. In one common application,connection device100 is utilized to create the capacitance values needed by a service or repair technician using a set of standard capacitors having specific capacitance values. This is accomplished by adding the desired additional capacitance to the capacitor section selected by choosing the clearly identified terminal of that particular capacitor section and by connecting the additional capacitance to be added to create the desired capacitance values. By obtaining the desired capacitance values through a combination of two or more capacitors, the number of capacitors that need to be taken to a service call at a remote site in order to ensure possession of the capacitance values needed for a repair is reduced.
• FIG. 7 is a perspective view of an exemplarycapacitor maintenance kit250.Capacitor maintenance kit250 includes astorage case252, a plurality ofcapacitors254, and a capacitor connection device, which in an exemplary embodiment isconnection device100.Storage case252 may include carryinghandles256 and258 to facilitate carrying ofcapacitor maintenance kit250.Storage case252 may also include dividers, for example,divider260, to separate each of the plurality of capacitors, and alsoseparate connection device100 from the plurality of capacitors.Divider260 also enables a user to quickly identify a missing capacitor, andstorage case252 may also include indicia indicating the capacitance value of the capacitor designed to be held in each divided segment ofstorage case252.
• Table 1 is an exemplary list of capacitors and associated capacitance values that may make up the plurality ofcapacitors254 included in one embodiment ofcapacitor maintenance kit250.

• 	TABLE 1
  		First	Second
  	Capacitor	Capacitance	Capacitance
  	number	Value (uF)	Value (uF)	VAC

  	1	5	—	370/440
  	2	10	—	370/440
  	3	20	—	370/440
  	4	15	5	370/440
  	5	30	5	370/440
  	6	35	5	370/440
  	7	35	7.5	370/440
  	8	40	5	370/440
  	9	40	7.5	370/440
  	10	45	5	370/440
  	11	45	7.5	370/440
  	12	50	5	370/440
  	13	50	7.5	370/440
  	14	50	10	370/440

• In this illustrated embodiment, of the fourteen capacitors, three are single capacitance value capacitors and eleven are dual capacitance value capacitors. When utilized withcapacitor connection device100, sixty-one capacitance value combinations are provided that may be used in an attempt to repair an HVAC/R system. Table 2 shows the capacitance value combinations that can be obtained using the fourteen capacitors and theconnection device100 of thecapacitor maintenance kit250.
• The individual capacitors, the capacitance values, and the number of capacitors incapacitor maintenance kit250 are examples only.Capacitor maintenance kit250 may include any number of capacitors with capacitance values predetermined to best suit the needs of specific service technicians.Capacitor maintenance kit250 may be stocked based on predictions of potentially necessary capacitance values based on commonly repaired systems. In the exemplary embodiment,capacitor maintenance kit250 includes fourteen capacitors. Eleven of the capacitors selected for exemplarycapacitor maintenance kit250 are multi-capacitance capacitors and three are single capacitance value capacitors. From the fourteen capacitors, sixty-one output capacitance combinations can be obtained.

• TABLE 2
  Capacitance
  Values (uF)
  Notes:

• In one illustrative example, an HVAC/R unit being repaired requires a 30 uF compressor capacitor and a 15 uF condenser capacitor. In order to obtain this combination of capacitance values, capacitor number 5 (see Table 1) and capacitor number 1 (see Table 1) are connected to the HVAC/R unit throughconnection device100. More specifically, the 30 uF terminal of capacitor number 5 is connected to thecondenser motor terminal120 ofconnection device100. The 5 uF terminal of capacitor number 5 is connected to thecompressor motor terminal122. Capacitor number 1 is connected toadditional capacitance terminal130 and the common terminals of capacitor number 1 and capacitor number 5 are connected tocommon terminals132 and124, respectively.Selection device114 is set to add the additional capacitance value to the condenser capacitor. The result is a 30 uF capacitor is provided to the compressor motor by capacitor number 5 and a 15 uF capacitor is provided to the condenser motor by a combination of capacitor number 1 and capacitor number 5.
• As described herein,capacitor maintenance kit250 andconnection device100 are configured to operate within a residential HVAC/R unit. However,capacitor maintenance kit250 andconnection device100 are not limited to use in residential HVAC/R systems and may also be a benefit in commercial HVAC/R systems and also in residential or commercial refrigeration systems. Furthermore,connection device100 is described herein as containing first set ofterminals110 and second set ofterminals112. However,connection device100 may include any number of sets of terminals, configured to couple any number of individual capacitor units, and will couple the individual capacitor units in the same manner of coupling first set ofterminals110 to second set ofterminals112 that is described above.
• The above-described methods and apparatus are cost-effective and reliable while still facilitating repair of an HVAC/R system, and more specifically, for replacement of HVAC/R unit capacitors. In addition, the combination of theconnection device100 andcapacitor maintenance kit250 provide the user the ability to use theconnection device100 to service a variety of HVAC/R units. Also, the kit enables a user to maintain a suitable inventory by placing an order for areplacement connection device100 and the used-up capacitor units from the kit at a lower cost that buying an entire new replacement kit. Consequently,connection device100 andcapacitor maintenance kit250 provide service personnel with the ability to create a broad arrange of capacitance values and combinations in a cost-effective manner.
• While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims (15)

1. A method for supplying a plurality of capacitance values to a plurality of heating, ventilation, air-conditioning, and refrigeration (HVAC/R) components, said method comprising:

configuring a first set of terminals of a connection device to couple a first capacitor to the connection device;

configuring the connection device to couple the first capacitor to at least one of the plurality of HVAC/R components;

configuring a second set of terminals of the connection device to couple a second capacitor to the connection device; and

configuring the connection device to selectively couple the second capacitor to at least one of the plurality of HVAC/R components.

2. A method according toclaim 1 wherein configuring the first set of terminals of the connection device to couple the first capacitor to the connection device comprises configuring the first set of terminals to couple a dual-rated capacitor unit to the connection device.

3. A method according toclaim 2 wherein configuring the connection device to couple the first capacitor to at least one of the plurality of HVAC/R components comprises configuring the connection device to provide a first HVAC/R component with a first capacitance value and a second HVAC/R component with a second capacitance value.

4. A method according toclaim 1 further comprising providing a plurality of capacitors, wherein the plurality of capacitors are selected to provide a predetermined variety of capacitance values when coupled by the connection device.

5. A method according toclaim 1 wherein configuring the connection device to selectively couple the second capacitor to at least one of the plurality of HVAC/R components comprises providing a visual indicator showing which of the plurality of HVAC/R components is coupled to the second capacitor.

6-11. (canceled)

12. A maintenance kit for servicing heating, ventilation, air-conditioning, and refrigeration (HVAC/R) systems, said HVAC/R system comprising a plurality of components, said kit comprising:

a plurality of capacitors of varied ratings, said plurality of capacitors selected to provide predetermined capacitance values when coupled; and

a connection device configured to couple capacitors selected from said plurality of capacitors to at least one component of said HVAC/R system.

13. A maintenance kit according toclaim 12 wherein said plurality of capacitors comprises a first set of capacitors and a second set of capacitors, said first set of capacitors comprising dual-rated capacitor units of varied ratings, and said second set of capacitors comprising single rating capacitors of varied ratings.

14. A maintenance kit according toclaim 13 wherein said connection device is configured to couple a capacitor from said first set of capacitors to at least one of said HVAC/R system components and selectively couple a capacitor from said second set of capacitors to at least one of said HVAC/R system components.

15. A maintenance kit according toclaim 14 wherein said connection device comprises at least one of a switch and a jumper-wire configured to selectively couple a capacitor from said second set of capacitors to at least one of said HVAC/R system components.

16. A heating, ventilation, air-conditioning, and refrigeration (HVAC/R) condensing unit comprising:

a compressor motor;

a condensing fan motor;

control circuitry configured to provide power to, and control operation of said compressor motor and said condensing fan motor; and

a connection device configured to couple said control circuitry, said compressor motor, and said condensing fan motor through at least one capacitor.

17. An HVAC/R condensing unit according toclaim 16 wherein said connection device is configured to selectively couple a plurality of capacitors to obtain a plurality of capacitance values.

18. An HVAC/R condensing unit according toclaim 16 wherein said connection device comprises at least one of a switch and a jumper-wire, configured to selectively couple said at least one capacitor to said compressor motor and said condensing fan motor.

19. An HVAC/R condensing unit according toclaim 16 wherein said connection device comprises a first conductor configured to couple a first contact of a first capacitor to a first HVAC/R component, a second conductor configured to couple a second contact of said first capacitor to said first HVAC/R component, and a third conductor configured to selectively couple a first contact of a second capacitor to one of said first HVAC/R component and said second HVAC/R component.

20. An HVAC/R condensing unit according toclaim 19 wherein said third conductor operable to selectively couple said first contact of said second capacitor to at least one of said first HVAC/R component and said second HVAC/R component further comprises selectively coupling such that a capacitance value of said first capacitor is added to a capacitance value of said second capacitor and provided to at least one of said first HVAC/R component and said second HVAC/R component.

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